Axminster carpet weaving



Sept. 24, 1957 J. H. PATRICK AXMINSTER CARPET WEAVING Filed Dec. 3l, 1953 veel..

United States Patent Oliice 21,807,286 Patented Sept. 24, 1957 2,807,286 AXWSTER CARPET WEAVING James H. Patrick, Montclair, N. J., assignor to Beattie Manufacturing Company, Little Falls, N. I., a corporation of New .Hersey Application December 31, 1953, Serial No. 401,501 9 Claims. (Cl. 139-401) The present invention relates to axrninster carpet weaving, including processes of weaving and fabrics thus produced.

A purpose of the invention is to obtain maximum eiciency of utilization of pile yarn in axminster carpet weaving, particularly in reference to maximum available `depth of pile for a given pile consumption, `and more effective utilization of the full depth of pile during the life of the carpet by supporting the pile Iat ya position well above the back of the fabric, and free from projection of the back above the points of locking of the pile.

A further purpose is to obtain a ilat back on an axminster carpet, comparable to the back which might be obtained in velvet and wilton carpet weaving.

A further purpose is to obtain uniform exibility in every direction in the back of an axminster carpet, avoiding directional properties in flexing of the back which limit the direction of rolling of the carpet.

A further purpose lis to obtain "a llat back in an axminster carpet without diiculty on account of grinning through of the pile to the back.

A further purpose is to obtain an improved bind in an axrninster carpet weave provided with a at back, as compared with prior art such yas the Imperial weave or the six pick repeat weave.

A further purpose is to employ less backing yarn in the back of a lat back iaxminster'carpet than is necessary in the Imperial or siX pick repeat weave by employing only one warp with maximum take-up instead of two.

A further purpose is to weave a three shot axminster carpet from 1a chain warp, stuifer warp, binder warp and tufts, by inserting one weft pair above the bind of the tufts, one weft pair immediately in back of the one just mentioned and behind the bind of the tufts and a second weft pair at the back behind the stuifer warp but longitudinally displaced from the weft pair rst mentioned at the ba-ck, to complete the weave locking the tufts behind the weft pair which is above the bind of the tufts and above the weft pair immediately behind the same, weaving the chain warp behind the second weft pair lat the back and above the weft pair which is above the bind of the tufts, weaving the binder warp behind the weft pair first mentioned at the back and above lthe second weft pair at the back, and weaving the stutter warp behind the one weft pair which is -above the bind of the tufts and above both weft pairs at the back.

A further purpose in weaving an axminster carpet is on the first step to lower the chain warp and raise the binder warp and stutter warp, insert a pair of wefts and beat up the wefts, on the second step raise the chain warp, lower the binder warp, raise the stuffer warp, insert a pair of wefts and beat up the wefts, and on the third step insert pile ruft ends, raise the Ichain warp, lower the binder warp and lower the stuifer warp, insert a pair of wefts, comb up Ithe tufts around the wefts if required and then beat up the wefts and tufts.

A further purpose in weaving in accordance with the present invention is to retain a relatively high tension on the stuifer warp ends, a relatively lower tension on the binder warp ends and a relatively still lower tension on the chain warp ends ythroughout weaving.

A further purpose in weaving in accordance with the present invention, is to draw up the warp end-s in each dent or course in the following order: binder warp end, chain warp end and stutter warp end, so as to hold the tufts more evenly spaced in the final weave.

A further purpose is selectively to obtain differential effects of the character of shadowing in the pile of fabric in accordance with the present invention by a draw-up sequence in each dent or course of the fabric which is: chain warp end, binder warp end and stuffer warp end.

Further purposes appear in the specification and in the claims.

In the drawings I have chosen to illustrate two only of the numerous embodiments in which my invention may appear, selecting the forms shown from the standpoints of convenience in illustration, satisfactory operation and clear demonstration of the principles involved.

Figure l is a longitudinal completed weave diagram illustrating the preferred embodiment of the present invention.

Figure 2 is a draw-up diagram showing a preferred embodiment of the draw-up employed in weaving in accordance with the present invention.

Figure 3 is a view Icorresponding to Figure 2, but showing ya variation.

In conventional aXrninster carpet weaving according to American practice, the back of the carpet has shown pronounced rib effects, which by many people `are believed to be characteristic of axminster weaving. In British practice for many years it has been conventional, however, to produce axminster carpets which have substantially flat backs free from this rib effect. Y

There are in some lcases advantages in employing a flat back on an axminster weave. |The flat back gives `a wider and more uniform load distribution, with less skidding Iand more tendency to maintain position on the lloor. The flat back also provides in the axminster weave a back appearance which is similar yto that of the Wilton, brussels and velvet carpet weaves.

By the present invention it is possible to obtain a ilatness of back construction which is comparable to that procured in these otherweaves.

As compared with the prior at back axminster woven in British practice, and known as the Imperial aliminster, or as the six pick repeat axminster, the present invention oiers the advantage that the grinning through of pile to the back can be avoided in the present invention, and -a much superior bind of pile tufts can be obtained, with a lower consumption of pile yarn and a lower consumption of backing yarn. The lower consumption of backing yarn is possible because there is only one pile warp woven with maximum take up, as compared with two pile warps so woven in the Imperial or six pick repeat weave.

By theY present invention, the fabric is essentially divided in depth and the parts of the back of the fabric are maintained in proper positionby the stuifer warp. The pile tufts are bound by wefts placed above the stutter Warp and held in that relation throughout the wear of the fabric, whereas there are two shots of weft or four weft ends which are maintained in the same plane behind the stuler warp for each weave repeat.

It will be understood that the wefts are inserted in pairs, so that two wefts or two picks correspond to one shot of weft.

' Thus an important aspect of the invention is that the stuier warp is directed straight throughout, with comparatively little serpentine bending in the fabric.

In the conventional ribbed back axminster carpet weaves, there is a tendency of the ribs to stick up at the front of the fabric on either side of the bind of the pile tufts. This protrusion of ribs at the front of the fabric has a tendency to pinch in upon the tufts or restrain the tufts from lateral diversion, .and thus reduces the coverage obtained from each pile row. In accordance with the present invention, however, it is not possible for any rib protrusion to occur above the bind of the pile tufts, and therefore the tufts are less restrained laterally, and thus give better coverage and more eflicient utilization of pile.

Furthermore in conventional axminster carpet weaving of the type having a ribbed back, the protrusion of the ribs' at the front of the carpet on either side of the bind of the tufts means that as the pile is worn down, the ribs in the backing will become visible before the pile is fully worn down, and a substantial amount of pile will remain after the carpet is effectively worn o ut and can no longer be used. In accordance with the present invention, on the other hand, there is very good coverage of the back until the pile is actually worn down nearly to the level of the bind of the weave, and there is no necessity for taking the carpet out of service due to the fact that ribs show through at the face of the carpet as in the prior art weave. Thus a more luxurious pile is obtained, and also a pile which will give longer service life per unit of pile height, and will permit maintaining the fabric in service until a larger proportion of the total pile yarn has been worn away. This advantage exists not only over the conventional ribbed back fabric, but also over other at back axminster fabrics.

A further advantage of the weave of the present invention is that the relatively continuous and flat course of the stuifer warp assures that the back will remain flatter than in prior art weaves where attempts have been made to produce flat backs on axminster carpet.

The invention gives an excellent bind of the tufts, sincey there are two binds for every three shots in the weave of the present invention. This is an advantage over certain of the prior art at back axminster weaves, which give only one bind for every three shots.

One of the practical difficulties in connection with axminster carpets is that they normally are flexible in the back only in one direction, and ordinarily can be rolled only in one direction. Therefore if the carpet is of rectangular shape, the direction of rolling may not be the most advantageous direction from the standpoint of producing a roll of minimum length for handling. The present invention overcomes this difficulty, and provides a carpet whose back is flexible in all directions, so that the carpet can be rolled equally well longitudinally or transversely, depending on the preference or conveniencel of the particular user.

The present invention is directed to a three shot axminster carpet weave, which is normally woven using a chain warp, a binder Warp, and a stuffer warp, together with three pairsof wefts for each repeat of the weave. In weaving according to the present invention, one of the weft pairs is placed in front of the bind of the tufts, one of the weft pairs is placedV immediately in back of the bind of the tufts, and Ya third weft pair is placedV at the back and behind the stufer warp but is longitudinally displacedwith respect to the weft pair which is immediately behind the bind of the tufts. The tufts are locked beind the weft pair which is above the stuifer warp, and in front of the weft pair which is immediately behind the same.' In weaving, the chain warp extends behind the second weft pair which is at the back 'of the fabric and in front of the weft pair which is above the bind of the tufts and also, of course, above the corresponding weft pair which is behind the 'bind of the tufts. The binder warp is woven behind the one weft pair which is at the beek ofthe f abri and. above the other weft pair which iS at the back of the fabric. The stuffer warp extends behind the weft pair which is above the bind of the tufts, and above both the weft pairs at the back of the fabric.

In weaving according to the present invention, the stuffer warp is placed under the relatively highest tension, the binder warp under a somewhat lower tension, and the chain warp under a still lower tension. The exact values of tension used will depend upon the weaving practice in the individual mill, the relative Weights of the particular warp ends concerned, and the relative diameters of the beams. As an example of current practice which has been used successfully in the present invention, but without intention to limit to the particular relationship stated, it has been found that a satisfactory ratio of the tension on the individual stuffer warp end, to the tension on the individual binder warp end, to the tension on the individual chain warp end, may be as ll is to 8 is to 5. It has been found that a chain warp tension comparable to the chain warp tension used in normal axminster weaving is satisfactory, for example of the order of 2.5 pounds per end.

Variations in the weave of the present invention can be obtained by varying the draw-up of the warps. From the standpoint of positioning the tufts uniformly and evenly in each course, it has been found to be desirable to employ the following sequence of ends in each dent or course: binder warp end, chain warp end and stutfer warp end. For certain preferential effects of the nature of shadowing of the pile, however, it is desirable to use a different order, and in this case the preferred draw-up may be: chain warp end, binder warp end and stuffer warp end in each dent or course.

Considering Inow the illustration of the weave of the present invention as shown in Figure l, it will be evident that I illustrate chain warp ends 20, binder warp ends 21, and stulfer warp ends 22, with pile tufts 23.

The order of insertion of the wefts in accordance with the invention will vary in any particular application of this weave, but it is preferable in accordance with the invention to insert the back weft pair 24 above the chain warp first, and then the back weft pair 25 above the binder warp, and lastly the tufts and the front weft pair 26.

Thus the sequence of weaving as illustrated in the table will preferably be as follows:

Table Step Chain warp Binder Stuter warp warp l Down Up Up. 2 Up Down... Up.

Insert pile tuft ends. 3 Up -do. Down.

Comb up tufts if required..

Step 1, the chain warp is lowered, the binder warp is raised, and the stuifer warp is raised. A shot of weft is inserted introducing weft pair 24 by the needle or other suitable mechanism as well known in the art, and at the end of the first step, this weft pair is beaten up by the lay.

On step 2, the shedding mechanism is changed, so that the chain warp is raised, the binder warp is lowered and the stuffer warp is raised. A shot of weft is inserted introducing weft pair 25 and the weft pair is beaten up by the lay.

At the beginning of the third step, the tube frame or other suitable mechanism inserts a row of pile tufts, and the chain warp is raised, the binder warp is lowered and the stuifer warp is lowered. A shot of weft is introduced, inserting weft pair 26k, the tufts are combed up if required, and then the weft pair and tufts are beaten up by the lay. This completes a weave repeat in accordance with the invention. It will be evident, of course, that in a nose board loomfthe tuft ends will be carried up instead of being combed up as well known in the art.

1f desired, the order of insertion of the weft pairs may be weft pair rst, weft pair 24 second and weft pair 26 third.

Desirable variations in the appearance of the fabric can be obtained by changing the draw-up. For most purposes it is preferred to use a draw-up as shown in Figure 2, which is the actual draw-up illustrated by Figure 1. In this form, a dent 27 is shown having splits 28 and 30 and typical of each dent in the reed. A binder warp end 21 It will, of course, be evident that if desired two or more ends of any particular function may be reeded and shedded together. It will of course be evident that this sequence can be used, and additional ends of any particular character can be placed adjoining Ione of the splits as long as the particular sequence is used together adjoining another split.

The draw-up of Figure 2 has the advantage of evenly spacing the individual tufts.

There may be an advantage in certain cases in creating special effects of the nature of shadowing of the pile, and for this purpose it may in some cases be desirable to use a draw-up of the character shown in Figure 3. In this case the sequence of ends from one split to the next in each dent may be chain Warp end 20, binder wrap end 2l and stutter warp end 22.

Conidering again the weave of Figure 1, it will be evident that the weft pair 26 binds in the tufts and is located behind the chain warp, above the stuffer warp and above the weft pair 25, which is immediately behind the weft pair 26 and supporting it. It will also be evident that the weft pairs 24 and 25 are at the back of the fabric substantially in the same plane and contributing to create a at back. It will furthermore be evident that the stufer warp 22 extends substantially straight or planewise longitudinally throughout the back of the fabric instead of being woven serpentine fashion in the back.

It will also be evident that the weft pair 24 at the back of the fabric is woven behind the binder warp and the stuler warp and above the chain warp and that the chain warp and binder warp cross on either side of this weft pair and between the weft pair 24 and the weft pair 25. The weft pair 25 is Woven above the binder warp and behind the stuffer warp and of course behind the chain Warp which goes over the front weft pair 26. Thus a very effective layering is maintained in the fabric.

It will be evident also that the bind at 31 of the tufts is placed well up in the fabric and above the stutter Warp and that there is no substantial ribbing eect on either side of the tuft, since the tuft is held between the front weft pair 26 and the back weft pair 25. It will also be evident that substantially all of the pile yarn is usefully employed in height of pile except that actually involved in the bind of the tuft, and that the pile can be worn down to a very low level without exposing the back of the fabric in areas not covered by the pile.

It will be evident that the fabric of the invention produces an extremely at back construction, with a maximum of the pile available in height of pile, and with a very Wide spread or coverage of the pile. It will also be evident that an excellent bind is obtained in the weave to hold the pile tufts in place.

The maintenance of the pile weft pairs 24 and 25 in the same plane assures that there will be a minimum depth of section in the back of the fabric, and gives a maximum of flexibility and uniformity of exibility of the back of the fabric in all directions, 'so that the fabric can be rolled either lengthwise or crosswise, as desired.

It will be evident also that the variation of draw-up and the choice of draw-up makes it possible to create novelty effects on the face of the fabric due to the tendency of the pile to remain oriented in a particular position when a particular draw-up is used.

In view yof my invention and disclosure variations and modications to meet individual whim or particular need will doubtless become evident to others skilled in the art, to obtain all or part of the benefits of my invention without copying the process and fabric shown, and I therefore claim all such insofar as they fall within the reasonable spirit and scope of my invention.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent is:

l. The process of weaving an axminster carpet having a flat back, which comprises as a first step lowering a chain warp, raising a binder warp, raising a stuffer warp, inserting a pair of wefts, and beating up the wefts, as a second step raising the chain warp, lowering the binder warp, raising the stutter warp, inserting a pair of wefts and beating up the wefts, as a third step inserting a row of tuft ends, raising the chain warp, lowering the binder warp, lowering the stutter war inserting a pair of Wefts which binds the tuft ends and beating up the pair of wefts.

2. The process of weaving according to claim l, in which the stutter Warp is maintained under relatively the highest tension, the binder warp is maintained under a lesser tension and the chain warp is maintained under a still lesser tension throughout the weaving.

3. The process of weaving according to claim 1, in which the sequence of draw-up in each dent is: binder warp end, chain warp end and stuffer warp end.

4. The process of weaving according to claim 2, in which the sequence of draw-up in each dent is: binder warp end, chain warp end and stulfer warp end.

5. The process of weaving according to claim l, in which the sequence of draw-up in each dent is: chain warp end, binder warp end and stulfer warp end.

6. The process of weaving according to claim 2, in which the sequence of draw-up in each dent is: chain warp end, binder warp end and stuffer warp end.

7. An axminster carpet weave, comprising chain warp ends, binder warp ends, and stutter Warp ends, lirst weft pairs bound below the chain warp ends and above the stuffer warp ends and the binder warp ends, second weft pairs below the rst weft pairs bound below the stulfer warp ends and above the binder warp ends, third weft pairs longitudinally displaced with respect to the rst and second weft pairs, bound below the binder warp ends and the stuifer warp ends and above the chain warp ends, and pile tufts bound between the first and second weft pairs, the second and third weft pairs lying in the same plane in the back of the fabric.

8. An axminster carpet weave according to claim 7, in which the sequence of arrangement of the ends in each course is: binder warp end, chain Warp end and stuffer warp end.

9. An axminster carpet weave according to claim 7, in which the sequence of arrangement of the ends in each course is: chain warp end, binder warp end and stuler warp end.

References Cited in the tile of this patent UNITED STATES PATENTS 

